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FILTERSYSTEME

Hydraulic training
16.10.2002 Filtration is the key to reliability and effective contamination control !

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Table of contents 1. Possible sources of solid-contamination of a hydraulic circuit.....................................................5 1.1. Added contamination ..............................................................................................................5 1.2. Inbuilt contamination ..............................................................................................................5 1.3. Generated contamination........................................................................................................6 2. Benefits of filtration.........................................................................................................................6 3. General requirements for filters .....................................................................................................7 4. Filter classification...........................................................................................................................8 4.1. Suction filter .............................................................................................................................8 4.1.1. The Mahle suction filter range.....................................................................................9 4.2. Pressure filter .........................................................................................................................10 4.2.1. The Mahle low pressure filter range .........................................................................11 4.2.2. The Mahle medium pressure filter range..................................................................12 4.2.3. The Mahle high pressure filter range ........................................................................13 4.3. Return line filter .....................................................................................................................14 4.3.1. The Mahle return line filter range..............................................................................15 4.4. Reservoir filters/air breathers ...............................................................................................16 4.4.1. The Mahle reservoir/ air breather range...................................................................17 4.5. Off-line/external loop filter/aggregate .................................................................................18 4.5.1. The Mahle off-line/external loop filter/aggregate range .........................................19 5. Filter designs..................................................................................................................................20
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5.1. Filter options ..........................................................................................................................20 5.1.1. Bypass .........................................................................................................................20 5.1.2. Contamination indicator (optical/electrical).............................................................21 5.1.3. Sampling valve ...........................................................................................................23 5.1.4. Under-/pressure manometers ...................................................................................24 5.1.5. Air breather.................................................................................................................25 5.1.6. Coupling for filling......................................................................................................26 5.1.7. Automatic air bleeder ................................................................................................27 5.1.8. Slosh baffle / filter strainer for air breathers ............................................................28 5.1.9. Preload valve ..............................................................................................................29 5.1.10. Reverse flow valve .....................................................................................................30 5.1.11. Cold start valve (bypassed flow returned to tank)...................................................31 5.2. Filter connections...................................................................................................................32 5.3. Filter seal material..................................................................................................................33 5.4. Filter element material ...........................................................................................................34 5.5. Filter element dimensions .....................................................................................................36 6. Filter characteristics ......................................................................................................................37 6.1. Beta-ratio/efficiency (multipass test according ISO4572) ...................................................37 6.2. Filter rating (m) ....................................................................................................................38 6.3. Collapse pressure (element, acc. to ISO 2941) .....................................................................40 6.4. Dirt holding capacity (multipass test according ISO4572)...................................................41 6.5. Initial differential pressure, = f(viscosity, flow rate).............................................................43 6.6. Fatigue strength (element and housing) ..............................................................................44
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6.7. Burst pressure (housing) .......................................................................................................45 6.8. Cleanliness classes for filter elements ..................................................................................46 7. Filter selection and sizing...............................................................................................................48 7.1. Required data for filter selection ...........................................................................................48 7.2. Filter sizing .............................................................................................................................49 8. Key for hydraulic filter elements and filter housings: ..................................................................51 8.1. Key for hydraulic elements according to Mahle standard: ..................................................51 8.2. Key for hydraulic elements according to DIN 24550: ...........................................................52 8.3. Key for hydraulic elements as replacement for competitor elements................................53 8.4. Key for oil separator elements ..............................................................................................54 8.5. Key for filter housings according to Mahle standard...........................................................55 8.6. Key for filter housings according to DIN 24550 ....................................................................56 8.7. Special keys............................................................................................................................57 9. Filter tests .....................................................................................................................................58 10. Lab facilities ..................................................................................................................................60 11. Further product information fine oil separators ......................................................................61

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1. Possible sources of solid-contamination of a hydraulic circuit 1.1. Added contamination contaminated air replenishing process worn piston rods/seals etc.

1.2. Inbuilt contamination cinder welding beads casting sand loose paint fibers from rags rust etc.

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1.3. Generated contamination wear erosion by abbrassive grit scuff from components particles generated by catalytic processes/oxidation - etc. -

2. Benefits of filtration - increased life expectancy of the fluid - significantly reduced risk of premature damage or failure of components - reduced repair, replacement and maintenance costs - avoided or at least minimized down time of the production - increased reliability and therefore increased production - increased life time of critical/expensive components

Scoring on a component of an axial piston pump

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3. General requirements for filters - low cost - easy recycleability of element - high efficiency - guarantee of cleanliness class - high dirt holding capacity - chemically resistant against fluid - resistant against pulsation - long service life - easy maintenance

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4. Filter classification The filter is graduated according to its position in the hydraulic circuit. 4.1. Suction filter Installed in suction line. Protection of pump. Cold start conditions must be considered because of possible cavitation. Point of time for element change by regular service intervals or contamination indicator.

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4.1.1.

The Mahle suction filter range

Suction filters Dp,ini < 0,1 bar PI 160 PI 1710 PI 270 all simplex pressure filters

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4.2. Pressure filter Installed in pressure line. Protection of specific components. Vibrations and pressure peaks should be avoided. (low/ medium/high-pressure) <63 bar / >63-210 bar / >210-450 bar Note: Duplex filters cannot be used in the suction line. Simplex filters can also be used as suction inline filter.

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4.2.1.

The Mahle low pressure filter range

Low pressure filters Dp,ini < 0,5 bar PI 150 PI 1500 PI 200 PI 210 (duplex) PI 220 (f-head+spin-on) PI 230 (Goldfilter) PI 270 (parallel filter) PI 2000 PI 1975 PI 1941 PI 1931 PI 1907 PI 5075

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4.2.2.

The Mahle medium pressure filter range

Medium pressure filters Dp,ini 0,5..0,8 bar E 1128 (in -/outlet on one side) PI 320 (parallel filter) PI 340 (in-/outlet on one side) PI 350 PI 360 PI 370 (duplex) PI 3000 PI 3300 PI 3700 (duplex) PI 3800 (duplex SS)

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4.2.3.

The Mahle high pressure filter range

High pressure filters Dp,ini <1 bar E 1128 (in -/outlet on one side) PI 410 (f-block) PI 420 PI 420 KV (cold start valve) PI 422 (L-connection) PI 430 PI 440 PI 450 PI 480 (ss) PI 1123 PI 4000 PI 4000 KV (cold start valve)

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4.3. Return line filter Installed in return line. Removal of contamination generated in the system as well as ingressed through seals. Filter can be used for topping-up hydraulic tank.

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4.3.1.

The Mahle return line filter range

Return line filters Dp,ini 0,2...0,5 bar PI 500 (option: double inlet for NG 40/NG 63) PI 510 (duplex design of PI 500) PI 530

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4.4. Reservoir filters/air breathers Installed on tank top. Air breathers can be integrated in the return line filter for air flows up to 250l/min (PI 5000/1-series). Note: The differential pressure curves are indicated for clean elements. In reality the oil vapour condenses in the element and leads to an increased differential pressure.

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4.4.1.

The Mahle reservoir/ air breather range

Air breather filters, Dp,ini <0,01 bar PI 0101-0185 PI 145-149 (PI0120-0126 with increased performance) PI 0120-0126 /UM PI 0126 AD

/UM...with integrated optical contamination indicator AD...air breather filter with air drier

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4.5. Off-line/external loop filter/aggregate Off-line filtration should be used to supplement existing filters Advantages of off-line filtration: independent from main circuit element is not subjected to transient conditions can be left running even when main system shuts down elements can be changed while the main system is running useable for charging new (old) oil into (out of) the system as supplement to partial flow return line filters (if full flow is not economical) very high dirt holding capacity increases service life for the other system filters low cost elements because of the low operating pressure online contamination control can (de-)activate off-line filter acc. to dirt concentration

Note: retention of off-line filter should be chosen finer than retention of the system filters.

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4.5.1.

The Mahle off-line/external loop filter/aggregate range

See leaflets: filter aggregates ( PI 1535-158, PI 1560-158) mobile filter aggregares PI 8100-series

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5. Filter designs 5.1. Filter options 5.1.1. Bypass The bypass protects the element from collapsing due to exceeding differential pressure. When the bypass valve opens the efficiency of the filter will drop. Filters without bypass must have an element with increased collapse strength (vst-design). Note: standard elements can be used in filters without bypass when the max. operating pressure does not exceed 20 bar. Filters with bypass are permissible for cleanliness classes lower than ISO 16/13 (ISO 4406)

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5.1.2. Contamination indicator (optical/electrical) Contamination indicators are strongly recommended for all filters to show when the element is clogged. Advantage: - reduces maintenance costs - prevents failure of elements - full use of dirt holding capacity

Options: single/two step (optical/electrical), signal suppression below 30 analog output, C, change over contact, etc. Note: Electrical upper parts with two steps need the corresponding mechanical indicator with two steps ! Standard electrical indicator are contact type normally closed-/normally opened and are mounted in normally closed position. By turning the electrical upper part 180 the , contact-type can be changed to normally opened.

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Electrical under-/pressure switches are often used for suction pumps and big air breathers. (See leaflet contamination indicators special leaflets, special indicator designs on request) +

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5.1.3. Sampling valve ...are used to check regularly the contamination level of the fluid. The sampling valve can be mounted instead of a contamination indicator or between filter head and contamination indicator.

A sampling valve is included in our Fluid sampling and adapter kit

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5.1.4. Under-/pressure manometers Under-/pressure manometers are often used for return line filters and suction filters. (See leaflet contamination indicators )

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5.1.5. Air breather Air breathers can be integrated directly in the return line filter. PI 500-serie for up to 100l/min. PI 5000/1-series for up to 250l/min. Bigger flow rates re quire an extra air breather.

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5.1.6. Coupling for filling Couplings for filling are often used for return line filters (see leaflet PI 500).

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5.1.7.

Automatic air bleeder

Automatic air bleeders can be used for low pressure filters up to 10 bar operating pressure e.g. for PI 150-series

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5.1.8.

Slosh baffle / filter strainer for air breathers

Slosh baffle for PI 0126 including filter strainer.


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5.1.9. Preload valve

Preload valve, expansion kit: p/n 9735382

Preload valve opening pressures: Inlet pressure: -50 mbar

Out let pressure: +200 mbar

Advantage:

- minimized ingress of humidity - support for pump


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5.1.10. Reverse flow valve Some applications require a possible flow in both directions. Normal filters are designed for one flow direction only. An opposite flow would damage the element. A reverse flow valve ensures both possible flow directions.
normal flow (filtration) reverse flow (no filtration)

Note: During reverse flow the fluid will not be filtered. The reverse flow valve can be delivered for high pressure filter series PI 420 with/without bypass.

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5.1.11. Cold start valve (bypassed flow returned to tank) Second outlet bypasses part of the inlet-flow back to the tank during excessive differential pressure (cold start, forgotten element change). Ensures that only filtered fluid exits from the main outlet connection. Unfiltered fluid is not bypassed to the clean side but returned to the tank. Available for the high pressure filter series: PI 420 (KV), nominal size 50, 80, 110 l PI 4000 (KV), nominal size 40,63,100 l Due to the bypass function, low pressure filter elements can be used.
tank outlet

inlet

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5.2. Filter connections flange (SAE, DIN, in-/outlet on one side or on opposite sides) pipe thread (cylindrical, conical) spin-on thread manifold block L-connection (90between in- and outlet) with cylindrical pipe threads or flanges

Special connections for the US-market according to file filters in US-design

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5.3. Filter seal material NBR (Buna N, Perbunan, max. 120 C) FPM (Viton, max. 180 C) EPDM (Buna AP, max. 130 C) PTFE (Teflon, max. 200 C) CR (Neoprene)

Attention: max. permissible operating temperature is limited to 120 because of the stability of C the glued seams of the filter element (special glues on request)!
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5.4. Filter element material - DRG wire mesh (cleanable, <60m immersion in ultrasonic bath recommended, surface filter)

- MIC-micronic organic (cellulose)

- Smx-super micronic, anorganic (multi-layer glas fibers)

- FIL (cellulose, extreme high dirt holding capacity but no defined retention, water absorption is possible - WS, standard material combined with a super absorber for water (see leaflet WS-elements) - KS, special material for coolants, efficiency like MIC 25
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f
Cleanable Initial Dp yes no no no no no Minimum retention low >10 m medium >5 m high >2 m high >2 no x ! m, medium/high >2 m medium Mic 25 Dirt holding capacity low medium high extreme high high medium Costs high low medium low/medium low

Filter media DRG Mic Smx FIL WS (water removal) KS (coolant lubricants)

Pleated stat design with Smxfilter material

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5.5. Filter element dimensions (see coresponding leaflets)

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6. Filter characteristics 6.1. Beta-ratio/efficiency (multipass test according ISO4572)


x = no. of particles > x upstream of filter no. of particles > x downstream of filter x 1 x
beta e(%) beta e(%) beta e(%)

The micron size at x=75 is most widely accepted as absoluterating.


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6.2. Filter rating (m)

b e t a r a t i o

e f f i c i e n c y %

particle size [m] Hydraulic training 14.08.2002 3IVA/Walter page 38/ 62

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e f f i c i e n c y %

particle size [m] Hydraulic training 14.08.2002 3IVA/Walter page 39/ 62

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6.3. Collapse pressure (element, acc. to ISO 2941)

Standard elements: VST-elements:

p,max = 20 bar p,max = 210 bar

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f
Multipass test booth

6.4. Dirt holding capacity (multipass test according ISO4572)

3g ISO-MTD (test dust)

This standardized test with test dust ISO-MTD determines the beta ratio and the dirt holding capacity of a filter element as function of the differential pressure.

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6.5. Initial differential pressure, = f(viscosity, flow rate) All p-curves are always measured with the various filter elements inside the corresponding housing size. Standard viscosities indicated: 33cSt, 190cSt p for other viscosities can be calculated with our hydraulic CD-rom or with the formula indicated in our filter guide, page 22

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6.6. Fatigue strength (element and housing)

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6.7. Burst pressure (housing)

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6.8. Cleanliness classes for filter elements Cleanliness classes are graduated according to : ISO DIS 4406 (>5m/>15m => class 1...24) most commonly used ! NAS 1638 (5-15m, 15-25m, 25-50m, 50-100m, >100m => class 00...12) SAE 749 D CETOP RP70H MIL STD 1246A NIST (see separate lecture)

Cleanliness classes graduates the dirt concentration of a fluid acc. to the number of particles with size Xm found within 100ml of fluid. Necessary cleanliness classes are specified by the components manufacturers depending on the internal clearances of components and the operating pressure.
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From our many years of experience, references for the selection of a certain filtermedia and filtration rate can be given according to the required cleanliness class:

Cross references between NAS- and ISO-cleanliness classes can be found in our filter guide.
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7. Filter selection and sizing 7.1. Required data for filter selection position in the hydraulic circuit max. operating pressure filter rating or required cleanliness class flow rate viscosity (during start-up and normal operation depending) - operating temperature - operating fluid/ material requirements - filter options/accessories

See questionnaire for fluid filters

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f
p,max,rec bypass [bar] <0,1 VA remark

7.2. Filter sizing Type of filter suction

low pressure medium pressure high pressure return line off-line/external loop air breather

<0,5 0,5...0,8 0,8...1 0,2...0,5

() () ()

<0,01

() VA or maintenance period (500h), danger of pump cavitation, VA if suction filter is only system filter, normally 100um, pump flow must be guaranteed at cold start p-resistance acc. system pressure p-resistance acc. system pressure p-resistance acc. system pressure p-resistance must be >p bypass at cold start deg, of filtration normally 3um, p-resistance acc. max. pump pressure () VA recommended for flow >2000l/min, retention acc. finest system filter, maintenance interval 3000-6000 hours

[] ()

... without bypass only if contamination class > ISO 16/13 is acceptable ... always ... never ... optional VA...contamination indicator
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Note: Choosing a larger filter capacity helps to:

- reduce running costs (less loss of energy) - increased service life - fewer element changes - reduced labour costs - reduced down time

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8. Key for hydraulic filter elements and filter housings: 8.1. Key for hydraulic elements according to Mahle standard: PI
10 = Mic 25 11 = Mic 10 21 = Sm-x 3 22 = Sm-x vst 3 31 = Sm-x 10 32 = Sm-x vst 10 41 = Sm-x 25 42 = Sm-x vst 25 51 = Sm-x 6 52 = Sm-x vst 6 71 = Drg vst 10 V2A 72 = Drg vst 25 V2A 73 = Drg vst 40 V2A 74 = Drg vst 60 V2A 75 = Drg vst 100 V2A 76 = Drg vst 200 V2A 77 = Drg vst 300 V2A 78 = Drg vst 500 V2A

1
91 = Drg vst 10 92 = Drg vst 25 93 = Drg vst 40 94 = Drg vst 60 95 = Drg vst 100 96 = Drg vst 200 97 = Drg vst 300 98 = Drg vst 500 99 = Drg vst. cylind.

05
05 = 08 = 11 = 15 = 30 = 45 = 60 =

Smx 10
50 80 110 150 300 450 600

filter material + retention 81 = Drg 10 82 = Drg 25 83 = Drg 40 84 = Drg 60 85 = Drg 100 86 = Drg 200 87 = Drg 300 88 = Drg 500 & cylindrical 89 = Drg 250/400/500

nominal size

Note: element without seal. Seal is integrated in filter head, not in element. Suitable filter housing has 4 digit model designation. Nominal size of element and housing must correspond. Example: PI 2005-058 with element PI 3105 Smx 10.

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8.2. Key for hydraulic elements according to DIN 24550:

PI

2
filter material 1= Mic 2= Smx 3= Drg 4= 5= 6= 7= Smx vst 8= Drg vst 9= 0=

3
retention 1= 3 m 2= 6 m 3 = 10 m 4 = 16 m 5 = 25 m 6 = 40 m 7 = 60 m 8 = 100 m 9 = 250 m 0= S = special

006

N Smx 10 NBR
seal material N = NBR E = EPDM F = FPM P = PTFE or PTFE capsuled C = CR

nominal size installation 004 = 40 D = pressure line 006 = 63 010 = 100 R = return line 016 = 160 025 = 250 040 = 400 063 = 630 100 = 1000

Note: seal included in element. Suitable filter housing has 5 digit model designation. Nominal size of element and housing must correspond. Example: PI 50006-058 with element PI 23006 RN.

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8.3. Key for hydraulic elements as replacement for competitor elements 890... 891... 892... 893... Hydac Pall Argo Internormen

Note: We offer crossreference data bases in Excel for competitors Hydac, Pall, Stauff, Parker and separate price lists for Hydac- and Pallreplacements.

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8.4. Key for oil separator elements 853... 852... wrapped elements pleated elements

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8.5. Key for filter housings according to Mahle standard Housings have a 4 or 5 digit model designation followed by a 3 digit code for the options.
PI 2 1= suction 2= low pressure 3= medium pressure 4= high pressure 5= return line 0 1=duplex 7= duplex 30 value*10=no minal size in l/min 058 code for filter options 012 = VAm5, Bp7 013 = VAe5, Bp7 014 = VAm5 015 = VAe5 057 = VAm2.2, Bp3.5 058 = VAe2.2, Bp3.5 068 = VAm2.2 069 = VAe2.2
VAm... VAe... Bp... 2.2/5/7 visual contamination indicator electrical contamination indicator Bypass valve switching level in bar

Beside of this general rule there are some exceptions as: low pressure filters PI 1941, PI 1975, PI 150 high pressure filter PI 1123 return line filter PI 1907, duplex filter PI 5075 etc.

Note: housing according to Mahle standard has 4 digit model designation (+ 3 digit model designation for filter options). Suitable filter element has 4 digit model designation, too. Example: PI 2005-058 with element PI 3105 Smx 10.
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8.6. Key for filter housings according to DIN 24550 Housings have a 5 digit model designation followed by a 3 digit code for the options.
PI 2 1= suction 2= low pressure 3= medium pressure 4= high pressure 5= return line 0 1=duplex 7= duplex 063 value*10=no minal size in l/min 058 code for filter options 012 = VAm5, Bp7 013 = VAe5, Bp7 014 = VAm5 015 = VAe5 057 = VAm2.2, Bp3.5 058 = VAe2.2, Bp3.5 068 = VAm2.2 069 = VAe2.2
VAm... VAe... Bp... 2.2/5/7 visual contamination indicator electrical contamination indicator Bypass valve switching level in bar

Note: housing according DIN 24550 has 5 digit model designation (+ 3 digit model designation for filter options). Suitable filter element has 5 digit model designation. Example: PI 20063-058 with element PI 23063 DN (Smx 10 NBR).
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8.7. Special keys Beside of known standard keys there exist some exceptions e.g. key for PI 422, PI 230 etc. (see corresponding leaflets)

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9. Filter tests

- multi-pass test according ISO 4572

- burst pressure test

- bubble point test according ISO 2942

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- initial differential pressure according ISO 3968

- collapse test according ISO 2941

- fatigue strength test according ISO 3724

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10. Lab facilities see filter tests microscopic contamination analyses particle analysis acc. ISO 4406/NAS 1638/NIST gravimetric contamination level according DIN 51592 [mg/l] determination of water content according to DIN 51577 IR-spectroscopy compatibility test for combinations of material and fluids ultrasonic cleaning of Drg-elements leak test determination of viscosity acc. DIN 51562 test of filterability

Prices for lab services acc. special price list.

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11. Further product information fine oil separators characteristics of oil separators: - max operating temperature 120 C - residue oil concentration: 1-3mg/Nm - vertical or horizontal mounting orientation - service life: approx. 5000 hours of operation - recommended air velocity: 0.06m/s => wrapped elements approx. 300cm /[Nm /h] => pleated elements approx. 400cm /[Nm /h] Note: residue oil concentration depends on sort of oil, temperature, air velocity, preseparation, design of filter housing, quality of oil separator. Service life is only limited by solid contaminants. Therefore good filtration of air and oil is the fundamental precondition. Our scope of supply is the fine oil separator element only !

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Appendix

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